Composite felt and process of making the same.



R. P. PERRY. COMPOSHE FELT AND PROCESS OF MAKING THE SAME.

APPLICATION HLED APR. 14, I917.

ATTORNEY Patented Dec. 17, 1918.

7 material, such as V often sticks or ad eres somewhat to the hot,

UNITED .sTA Es PATENT OFFICE.

BAY P. PERRY, OE U PPER MONTCLAIR, NEW JERSEY, ABBIGNOB TO THE BARRETT COMPANY, A CORPORATION 01' NEW JERSEY.

conrosrrn ram new raoonss or Mannie 'rnn slam.

Specification of Letters Intent.

Application filed April 1!, 1917. Serial No. 102,121.

To all whom it may concern:

Be it known that I, RAY P. Pnnm', a citizen of the United States, residin at Upper Montclair, in the county of ssex an State of New Jersey, have invented certain new and useful Improvements in Comgosite Felts and Processes of Making the ame, of which the following is a specification.

This invention relates to dry -felts or papers used for making roofing, or construction materials or for use as sheathin or building apers and for other uses. lhe

felt whic I is the' object of my invention contains, while still in the dry state, a predetermined proportion of bituminous material in comminuted form, as in filamentary form, for example.

Such bituminous dry felts or papers have been described and-claimed in my copemL ing application bearin Serial Number 161, 670 filed April 12, 191 I In the manufacture of d felts containing a certain proportion of l iituminous material in comminuted form, difliculty ,is sometimes experienced in, manufacturing such felts due to the fact that in the drying operatiomwhich is a necessary step in the manufacture of such felts if the felt contains a high percentage [of V itch or asphalt, the same driving rolls with the result that suc rolls co lect some bituminous material an may, as a result of such collected material, injure or'dama the surface of the roofing ma: terial. uch adhesion also reduces the heat transmission and hence the efiiciency of such rolls for drying purposes. This difliculty is experienced especially when the dry fe lt, containing the comminuted bituminous material, has a high percentage of such material, though some difliculty may "be experienced with felts containing a lower percentage of such bituminous material especially where the drying rolls are very hot.

Bymy method such difliculties are entirely avoided. Moreover it is ossible by my method to prepare a .dry fe t or paper containing a very large percentage of bituminous material in, comminuted form. In fact in some cases a, larger percentage may be obtained than would be at all pos bituminous sible or feasible without the application of my lnvention.

- These, and other desirable objects, are obtained in the following manner:

Instead of making the felt in a single uniform sheet or layer consisting of a predetermined mixture of bituminous filaments or bituminous material in any other commlnuted form added to the usual pul mixture consisting of rags and paper, make the dry bituminous felt in the form of a composite sheet. My mode of procedure is as follows:

Instead of havin a singleforming cylinder and couch r0 I have a plurality of such cylinders and correspondin couch rolls, generally three in number. The composite sheet which is the object of my in- ,vention is made in three la e'rs generally. The. intermediate .layer is ormed with a very high percentage of bituminous comminuted material in the same. The surface layers, however, either contain no bituminous material at all or contain such ma drying rolls together where, under the action of the dryingrolls, the. layers are further cemented or fused together into a sin 1e com osite sheet. This cementing is facl itated y the fact that the intermediate layer rich in bituminous material is slightly softened or fused by the heat from the dry ing rolls and accordingly acts as a cementin a nt'. For a similar reason'it is possib e my process to make a felt of any desir thickness, since the usual diliiculty experienced in the splitting a art of felts of great thickness when forme in separate sheets or layers in a severallinder paper machine, is avoided due to t e cementing action of the intermediate layer or layers rich in bituminous material. No matter how thick the composite sheet may be, the

Patented Dec. 11,j,9 18.

'65 nous material I intermedim layer prevents any separation or splittin apart of the component sheets after the ormation of the felt since said lafir acts as a cementing agent.

y invention comprises the product as well as the process.

Referring to the drawing wherein l have illustrated my invention, Figure 1 shows diametrically a device wherein my process may be ractised and my product may be produce Fig. 2 shows in ma ified cross-section the composite felt whic is the result of my invention.

Fig. 3 shows in magnified cross-section a modified composite sheet made up of two lavers only.

The composite sheet which is the object of my invention is made as follows:

1 is a layer (ontaining a large percentage of omminuted bituminous material, such as soft or hard coal tar pitch, asphalt or other solid bituminous material, resins, petroleum or still want, stearin pit'h, cotton-seed pitch or analogous material in the form of regular or irregularfragments, powder, shot, filaments, or fragments of the same, etc., as described in m copending application above referred to. ereafteryin the specification and claims I shallrefer tothese classes of materials under the common designation of bituminous materials.

The sto k from which this in addition to comminuted bituminous material (generally amounting, if desired, to more than and less than 90% of the total stock), consists of a mixture of rags and paper in the form of a watery pulp, the whole bein intimately mixed together, all as describe in my copending applies tion above referred to. As a result of the addition of comminuted bituminous mate rial, especially when such material is in filamentary form, I may use a larger proportion of paper or hard stock, and a smaller proportion of rage or soft stock than has itherto been dwmed feasible, and still leave the roofing material open and orous enough for subsequentisaturation. his result is due. to the fact that the particles of bituminous material, especially when the same are of filamentary form, are scattered through the roofing mafterial and serve, to a certain extent, 'to spread. and keepisuch material open and porous. I may use, to example, 'a mixture containing 50% of ituminous -material in comminutedform, 25% rags and 25% paper in the form of a watery pulp, with co'nsi erable success.

This mixture S, is-placed. in the inner cylinder vat 4. of a several-cylinder papermaking machine M, the outer cylinder vats 4;,rontainin a wate pulp of paper-making materia containing either no bitumiin comminuted form, such as layer is made,

means filaments of pitch or fragments thereof, or else containing such material in proportions which willnot cause the layers 2, 3 formed from the mixtures S and S, in the cylinder vats 4 to adhere to the drying rolls during the drying operation. Any number or arrangement of the cylinder vats 4 4,, 4-,,

7 ing r0 1 orrolls or other dryin means con- In practice the nous material to may be employed, three being shown as arranged in the drawing merely by way of illustration.

Within the cylinder vats 4 4,, 4,, are the respective perforated cylinders 6 6,, 6,, c0- operating with the wet felt endless belt 8 andthe couch rolls 7,, 7., 7 to. form the component layers 2, 1 and 3, respectively, '80 of the composite sheet 5. The layer 2 poor in comniinuted bituminous material or containing no su;h materialat all is formed from the material 8,, in the vat 4 being carried on the under side of the wet felt 8 until it picks up the layer 1 rich in bituminous materia the layer 1 bein made from the material S in the vat 4,. The wet felt 8, now carrying a composite sheet made up of the two layers 2, 1, the layer 2 being in contact with thefelt and the layer 1 being in contact with the layer 2, picks up the further layer 3, poor in comminuted bituminous material or containing no such material at all, so that the composite sheet 5, after it leaves the last couch roll, consists of three layers, 2, 1, 3, the intermediate layer 1 being rich in comminuted bituminous material and the outer layers 2, 3 being poor in such material, or containing no such we material at all. After leaving the wet felt,

the composite sheet 5 is dried in the manner customary in the manufacture of paper by being passed over a series of steam-heated drying rolls or in any other desired manner.

layer 1 contains generally more than 30% of comminuted bituminous material and the outer layers 2, 3 less than 40% of such bituminous material. These percentages, however, may be varied at will, the controlling condition being that while the intermediate layer 1 maybe as rich as desired in comminuted bituminous material.

the outer layers2, 3, should contain a low enough percentage ofcomminuoed bitumisubstantially prevent the composite felt from sticking tothe drying rolls during the drying operation. here the d ing is caused to proceed from a dry- 1'20 tacting'with but one side of t e composite felt, a composite felt 5" may be made consisting of but one layer 2' of material poor in comminuted material and another layer 1' rich in such material, the composite sheet 5 assing over the drying roll or other heating device in contact with that side of the composite sheet which is covered by the layer 2' poor in, oomminutedbituminous material. 1B0

v applying the same after the sheets are The action of the drying roll or rolls helps to cause the component layers to unite, and the bituminous material present in the layer rich in bituminous material furthers the uniting action b being somewhat softened or fused by the cat from the drying rolls, thereby cementing the composite sheet into a strong unitary structure. The composite sheet whether consisting of two, three on more layers, may be saturated with waterproofing material, or coated with such or analogous material, or both, in the manner usual in the manufacture of so-called rubber roofings. Usually the waterproofing and coating material consists of bituminous materials such as pitch or asphalt. While the thickness of the composite layers may be varied at will, and while the relative proportions in the thickness of the complete sheet of each of the component layers may be varied as desired, it is customary to make the layer rich in bituminous material com paratively thick and the layer or layers poor in comminuted bituminous material comparatively thin, thereby providing the composite sheet with a maximum content of bituminous material.

The component sheet, however, need not be saturated but may be used in the dry state. For example, I may'make dry sheathing or dry paper by my process. In such case the watery pulp stock may for all purposes be made largely or entirely of old papers or similar material and, if desired, the outer layers may be colored red, blue, etc., either by mixing color with the stock or by later formed. The interior layer or layers may be rich in bituminous material in solid form and serve to make the sheathing paper more damp resistant, and have other advantages. The composite sheet may obviously be made in various combinations and used for a variety of purposes. 7

Throughout the specification and claims wherever I refer to material as being poor in bituminous matter, or as containing a smaller or a comparatively small proportion of such matter, I mean to include by such terms those instances where the material contains no bituminous matter at all.

What I claim is:

1. A composite strip of paper comprising a layer of material containing a predetermined quantity of fusible bituminous mat ter in comminuted form, and at. least one other layer of material united to the first layer and containing a smaller proportion of layer and containing a smaller proportion of bituminous matter in comminuted form than said first-mentioned layer, substantially as described.

3. A composite strip of paper comprising a layer of material containing a predetermined quantity of comminuted bituminous matter and two other layers of material united to the first layer, one on each side of said first-mentioned layer and each .containing a smaller pro ortion of bituminous matter in comminute form than said firstmentioned layer, substantially as described.

4. A composite strip of paper comprising a layer of material containing a predetermined quantity of fusible waterproofing matter in comminuted form, and at least one other layer of material united to the first layer and containing a smaller proportion of waterproofing matter than said first-mentioned layer, substantially as described.

5. A composite strip of paper comprising a layer of material contaming a predetermined quantity of comminuted fusibl waterproofing matter and two other layers of material united to the first layer, one on each side of said first-mentioned layer and each containing a smaller proportion of waterproofing matter than said firsfimentioned layer, substantially as described.

6. A composite strip of aper comprising a layer of material containing between 30% and 90% of fusible comminuted bituminous matter, and at least one other layer of material united to the first layer and containing less than 40% of bituminous matter, substantially as described.

7. A composite strip of paper comprising a layer of material containing more than 30% of fusible comminuted bituminous matter and two other layers of material united to the first layer, one on each side of said first layer, and containing each less than 40% of bituminous matter, substantially as described.

8 The process of making paper which comprises the steps of forming a layer of material containin a comparatively large proportion of fusi le comminuted bituminous matter, forming a second layer of material containing a comparatively small quantity of bituminous matter, and causin said layers to become united in an integra sheet, substantially as described.

9. The process of making paper which comprises the steps of forming a layer of material containing a comparatively small quantity of bituminous matter, forming a second layer of material containin a comparatively large proportion of fusible com minuted bituminous matter, forming a third layer of material containing a comparatively small proportion of bituminous matter, the second-mentioned layer being 10- cated between the othe two layers, and causing said layers to become united into a single composite sheet, substantially as described.

10. The rocess of making paper which comprises t e steps of forming a layer of material containing a comparatively large proportion of comminuted bituminous mata ter, forming a second layerof material containing a comparatively small quantity of comminuted bituminous matter, and causin said layers to become united in an integra sheet,substantially as described.

11."The rocess of making paper which comprises t e steps of forming a layer of material containing a comparatively small uantity of comminuted bituminous matter,

orming a second layer of material containing a comparatively large proportion of comminuted bituminous matter, forming a third layer of material containing a comaratively small proportion of comminuted ituminous matter, the second mentioned layer'being located between the other two layers, and causing said layers to become united into asingle composite sheet, substantially as described.

12. The process of makin paper which comprises the steps of forming a layer of material containing a comparatively small proportion of comminuted bituminous matter, forming a second layer of material containing a comparatively large proportion of comminuted bituminous matter, and heating said layers to cause the same to become united into a unitary sheet, the union being assisted due to the cemented action of the comminuted bituminous material present in the sheet, substantially as described.

13. The process of making paper which consists in forming a sheet. containing comminuted fusible waterproofing matter, applying thereto one or more layers of paper containing a smaller proportion of waterproofing material and drying the same.

In testimony whereof I aflix my signature.

RAY P. PERRY. 

